The Cost of Poor Packaging
Freight damage claims cost the shipping industry billions annually, and the vast majority are preventable. Carriers will deny claims if they determine that inadequate packaging contributed to the damage — even if the carrier's handling was rough.
The standard is simple: your freight must be packaged to withstand normal transportation conditions, including multiple handling points, stacking, vibration, and temperature changes.
Palletization Standards
Pallet Selection
- Use Grade A or #1 pallets — no broken boards, protruding nails, or missing blocks
- Standard size is 48" x 40" GMA pallets for most LTL freight
- Ensure the pallet can support the total weight with a safety factor of 3x
- Four-way entry pallets are preferred for forklift access from any side
Stacking on the Pallet
- Stack boxes in a columnar or interlocking pattern
- Keep the load within the pallet footprint — no overhang
- Place heaviest items on the bottom
- Use corner boards to stabilize the stack and distribute strap pressure
- Maximum pallet height: 48 inches for most LTL carriers (including pallet)
Securing the Load
- Stretch wrap: Minimum 3 revolutions at the base anchoring freight to pallet, then wrap entire load with at least 3 full layers. Use 80-gauge film minimum.
- Banding: Use polyester or steel banding for heavy loads over 2,500 lbs. Minimum 2 bands per pallet.
- Corner boards: Use on all four corners for loads over 1,000 lbs or when banding.
Crating and Skidding
For high-value, fragile, or irregularly shaped items:
- Use heat-treated lumber compliant with ISPM-15 for international shipments
- Interior should have foam, bubble wrap, or molded packaging contacting the item on all six sides
- The item should not be able to shift more than 1/4 inch in any direction
- Mark crates with handling instructions: "FRAGILE," "THIS SIDE UP," directional arrows
Loose Freight and Cartons
- Double-wall corrugated boxes for items over 30 lbs
- Fill all void space — items should not shift inside the box
- Seal with 2-inch pressure-sensitive tape, applied in H-pattern (center seam plus edges)
- Each carton should be individually labeled with shipper and consignee info
Freight That Needs Extra Attention
Electronics: Anti-static packaging, foam inserts, "FRAGILE" marking. Consider double-boxing.
Glass and ceramics: Individual wrapping, cell dividers, crush-resistant outer container.
Machinery and equipment: Bolt or bracket to skid. Drain all fluids. Protect exposed surfaces.
Temperature-sensitive goods: Insulated packaging, gel packs or dry ice, temperature monitors.
Documentation for Claims Protection
Even with perfect packaging, photograph your freight before it ships:
- Photos of the product before packaging
- Photos of the completed pallet/crate from all four sides
- Close-ups of stretch wrap, banding, and labels
- Weight slip if available
This documentation is your evidence if a claim is filed. Without it, carriers routinely cite "insufficient packaging" to deny claims.
Unsure if your packaging meets carrier requirements? Send us photos and we'll advise before you ship.